Input shaft grooved ball bearing, replacing in uninstalled but not disassembled transmission

Special tools, testers and auxiliary items required 

Fig 1: Driving Sleeve 32 - 109

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• Driving sleeve 32 - 109

Fig 2: Tapered Roller Bearing Puller V.A.G 1582

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• Taper roller bearing puller V.A.G 1582
• Attachment V.A.G 1582/12

Fig 3: Identifying Bolt, Leaf Spring & Clutch Release Lever

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• Loosen bolt - 1  - and remove leaf spring - 2  -.
• Remove clutch release lever - 3  - with release bearing.

Fig 4: Identifying Bolts, Securing Plate, Guide Sleeve & Intermediate Piece

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• Remove bolts - arrows  - and securing plate - 1  -.
• Pull a thin insulating hose or heat-shrinkable hose over input shaft splines.
• Pull guide sleeve - 2  - out of transmission housing.
• Remove intermediate piece - 3  - from transmission housing.

Fig 5: O-Ring Remove/Install Components

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• Pry out O-ring - arrow  - with a small screwdriver.

Fig 6: Removing Input Shaft Circlip

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• Circlip - arrow  - in front of grooved ball bearing of input shaft must then be removed.

Fig 7: Removing Input Shaft Grooved Ball Bearing From Transmission Housing

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• Remove input shaft grooved ball bearing from transmission housing.
• Then slide new grooved ball bearing on input shaft.

Installation position:

Closed side of cage for balls points toward transmission housing.

Fig 8: Driving Grooved Ball Bearing In Transmission Housing To Stop

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• Drive grooved ball bearing in transmission housing to stop.

Fig 9: Removing Input Shaft Circlip

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• Circlip - arrow  - in front of grooved ball bearing of input shaft must then be installed.

Fig 10: O-Ring Remove/Install Components

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• Coat new O-ring - arrow  - with transmission fluid before installing in surrounding groove in transmission housing.
• Fill space between sealing lip and dust lip on sealing ring in guide sleeve halfway with grease G 052 128 A1  .
• Lightly lubricate outer circumference of guide sleeve.

Fig 11: Identifying Bolts, Securing Plate, Guide Sleeve & Intermediate Piece

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• Slide guide sleeve - 2  - over input shaft in transmission housing.
• Remove insulating hose or heat-shrinkable hose.
• Attach securing plate - 1  -.
• Clean bolt threads - arrows  - with a wire brush. Then insert screws with locking compound AMV 185 101 A1  and tighten to 24 Nm.

• Insert intermediate piece - 3  - in transmission housing.

Fig 12: Identifying Bolt, Leaf Spring & Clutch Release Lever

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• You must lightly coat contact surface of clutch slave cylinder plunger with copper paste before installing clutch release lever - 3  -.
• Install clutch release lever with release bearing.
• Clean bolt threads - 1  - with a wire brush.
• Place leaf spring - 2  - on bolts - 1  -.

• Then insert bolts - 1  - with locking compound AMV 185 101 A1  and tighten to 24 Nm.